Additive manufacturing of an ultrastrong, deformable Aluminum alloy

A recent study published in Nature Communications details the development of a novel aluminum (Al) alloy, Al92Ti2Fe2Co2Ni2, fabricated through selective laser melting (SLM). This alloy exhibits exceptional mechanical properties, achieving a strength exceeding 700 MPa while maintaining significant plastic deformability. Traditional high-strength Al alloys, such as AA 7075, are often unsuitable for additive manufacturing due to their tendency to crack during solidification. The new alloy incorporates nanoscale medium-entropy intermetallics, which form heterogeneous microstructures that enhance strength and ductility.

The research highlights the formation of nanoscale intermetallic lamellae within the alloy, which contribute to its mechanical performance. Compression tests reveal that certain regions of the alloy can achieve flow stresses over 900 MPa, attributed to complex dislocation structures and stacking faults in the intermetallic phases. The study suggests that the strategic introduction of these nanoscale intermetallics can provide a viable pathway for designing ultrastrong, deformable Al alloys suitable for various industrial applications, particularly in aerospace and automotive sectors.

Overall, this work represents a significant advancement in the field of additive manufacturing, demonstrating the potential for creating high-performance materials that combine strength and flexibility through innovative microstructural engineering.